Spirally wound channel core

ABSTRACT

A spool has a spirally-wound, elongated channel having a C-shaped cross-section with a pair of arms extending from a central web. The channel is oriented with the pair of arms parallel to the axis of the spool and with the central web extending radially, relative to the axis of the spool. The channel has a plurality of adjacent windings, a first and second of the arms of spirally-wound channel cumulatively forming the inner and outer surfaces of the spool. The arms are spaced apart a distance approximating the width of the central web, such that the central web of the windings of the channel is received between the arms of adjacent windings and is retained therein to establish an overlap of windings in the axial direction. Other embodiments feature S, B and E-shaped channels to form the spool, some embodiments having inner and outer layers of channel. The spool is suitable for holding wound, thin metal stock, such as aluminum for making beverage cans, having a smooth outer surface which preserves the smoothness of the wound stock.

FIELD

The present invention relates to spools or “cores” around which thinstock materials, such as sheet metal, metal foil, wire, fabric or rope,may be wound to allow storage, transportation and/or handling of suchstock materials, and more particularly, to such spools made fromspirally wound material.

BACKGROUND

Coiled products, such as aluminum sheet and foil, must be stored on andtransported to customers using a central spool or core about which theproduct is wrapped. The dimensions and characteristics of such cores aregenerally specified by the customers, and must be compatible with thecustomers' coil handling systems and minimize product damage duringshipping and handling. For example, for high-volume, coiled aluminumsheet products, such as can stock, end stock and tab stock (all used inthe manufacture of the aluminum beverage can), the cores used aretypically thick walled tubes of laminated Kraft paper. Alternatives topaper cores, e.g., metal cores constructed by overlapping a corrugatedstrip into a spiral form around a mandrel are known.

SUMMARY

The disclosed subject matter overcomes the disadvantages andshortcomings of the prior art by providing a spool having an axis, anaxial length, an inner surface and a curved outer surface about whichmaterial may be wound. The spool has a spirally wound, elongated channelhaving a C-shaped cross-section with a pair of arms extending from acentral web, the channel being oriented with the pair of arms having acomponent of extension parallel to the axial length of the spool andwith the central web extending radially relative to the axis of thespool. The channel has a plurality of adjacent windings, a first of thearms of spirally wound channel cumulatively forming the outer surfaceand a second of the arms of spirally wound channel cumulatively formingthe inner surface, the first arm and the second arm spaced apart adistance approximating the width of the central web, such that thecentral web of the windings of the channel is receivable between thearms of adjacent windings and is retainable therein to establish anoverlap of windings of the channel in the axial direction.

In accordance with an embodiment of the present disclosure, each of thefirst arm and the second arm has a first portion extending from thecentral web and a second portion extending from a free end of the arm toa transition portion extending between the first portion and the secondportion, the second portion of the first arm and the second portion ofthe second arm having a first spacing there between approximating asecond spacing between an exterior surface of the first portion of thefirst arm and an exterior surface of the first portion of the secondarm.

In accordance with another embodiment of the present disclosure, thechannel exhibits a third spacing between an exterior surface of thesecond portion of the first arm and an exterior surface of the secondportion of the second arm and the difference between the second spacingand the third spacing approximates a radial thickness of the secondportion.

In accordance with another embodiment of the present disclosure, theouter surface of the spool is cylindrical and smooth.

In accordance with another embodiment of the present disclosure, atleast one of the first arm and the second arm has an undulating form incross-section, an interior surface of the undulating form engaging andmating with an exterior surface of an undulating form of an adjacentwinding of the channel of the spool.

In accordance with another embodiment of the present disclosure, both ofthe first arm and the second arm have an undulating form incross-section.

In accordance with another embodiment of the present disclosure, theundulating form has first and second bulges separated by a valley, thefirst bulge extending from the central web.

In accordance with another embodiment of the present disclosure, thechannel has at least one slot extending into the central web, the slotcapable of receiving an end of at least one of the first arm and thesecond arm of an adjacent winding of the channel.

In accordance with another embodiment of the present disclosure, theslot is blind and is angled at an acute interior angle relative to thecentral web.

In accordance with another embodiment of the present disclosure, thechannel has a pair of slots, a first slot disposed proximate a junctionof the first arm with the central web and a second slot disposedproximate a junction of the second arm with the central web.

In accordance with another embodiment of the present disclosure, thefirst arm and the second arm each have an angled portion proximate afree end thereof which inserts into a corresponding one of the firstslot and the second slot of an adjacent winding of the channel.

In accordance with another embodiment of the present disclosure, thechannel has at least one groove in at least one of the first arm and thesecond arm disposed proximate the central web, and wherein at least oneof the first arm and the second arm has an angled portion proximate afree end thereof which inserts into the groove of an adjacent winding ofthe channel.

In accordance with another embodiment of the present disclosure, the atleast one groove is disposed between the central web and the first arm.

In accordance with another embodiment of the present disclosure, the atleast one groove has a generally V-shaped cross-section.

In accordance with another embodiment of the present disclosure, atleast one of the first arm and the second arm has a plurality ofopenings formed therein and from which a tab depends at an anglerelative thereto proximate at least one of the openings, at least one ofthe plurality of openings aligning with the tab of an adjacent windingof the channel, the tab inserting into the aligned opening and aiding insecuring adjacent windings of the channel in relative juxtaposition.

In accordance with another embodiment of the present disclosure, a spoolhas an axis, an axial length, an inner surface and a curved outersurface about which material may be wound and a spirally wound,elongated channel having an S-shaped cross-section with a pair of armsextending from a central web and having a component of extension inopposite directions. A first arm of the pair of arms has a firstextension extending from an end of the first arm distal to the centralweb at an angle relative to the first arm and forming a top portion ofthe S-shape. A second arm of the pair of arms has a second extensionextending from an end of the second arm distal to the central web at anangle relative to the second arm and forming a bottom portion of theS-shape, the second extension pointing towards a portion of the centralweb. A distal end of the second extension is distal to the second armand is spaced from the central web by a first spacing, the channel beingoriented with the pair of arms having a component of extension parallelto the axial length of the spool and with the central web extendingradially relative to the axis of the spool. The channel has a pluralityof adjacent windings, the first arm of adjacent windings of spirallywound channel cumulatively forming the outer surface and the second armof adjacent windings of spirally wound channel cumulatively forming theinner surface, the first extension being receivable between the distalend of the second extension and the central web of an adjacent windingto interlock therewith and establish an overlap in the axial direction.

In accordance with another embodiment of the present disclosure, thedistal end of the second extension pushes the first extension of anadjacent winding of the channel toward the central web.

In accordance with another embodiment of the present disclosure, apushing arm extending from the distal end of the second extension, thepushing arm being captured in the interior angle formed between thefirst extension and the first arm.

In accordance with another embodiment of the present disclosure, a spoolhaving an axis, an axial length, an inner surface and a curved outersurface about which material may be wound has a spirally wound,elongated inner channel with a first central web and a first pair ofarms spaced a first distance from one another. The inner channel isoriented with the first central web having a component of extensionparallel to the axial length of the spool and with the first pair ofarms extending therefrom at least partially in a radial direction awayfrom the axis of the spool. The inner channel has a plurality ofadjacent windings, the first central web of adjacent windings ofspirally wound inner channel cumulatively forming the inner surface. Aspirally wound, elongated outer channel has a second central web and asecond pair of arms spaced a second distance from one another. The outerchannel is oriented with the second central web generally parallel tothe axial length of the spool and with the second pair of arms extendingtherefrom at least partially in a radial direction towards the axis ofthe spool. The outer channel has a plurality of adjacent windings, thesecond central web of adjacent windings of spirally wound outer channelcumulatively forming the outer surface. The outer channel is wound overthe inner channel with one of the first pair of arms positioned betweenthe second pair of arms, such that adjacent windings of spirally woundouter channel bridge adjacent windings of spirally wound inner channellimiting axial motion of the outer channel relative to the inner channeland limiting spacing between adjacent windings of the inner channel andspacing between adjacent windings of the outer channel.

In accordance with another embodiment of the present disclosure, thefirst pair of arms converge towards one another at a distal end thereofand the second pair of arms converge towards one another at a distal endthereof, the first pair of arms with the first central web forming atriangular shape and the second pair of arms with the second central webforming a triangular shape.

In accordance with another embodiment of the present disclosure, a firstarm of a first adjacent winding of the outer channel and a second arm ofa second adjacent winding of the outer channel are disposed within afirst triangular shape of a first adjacent winding of the inner channel.

In accordance with another embodiment of the present disclosure, aplurality of adjacent windings of the inner channel each capture thefirst arm and the second arm of adjacent windings of the outer channelwithin the triangular shape, thereby interlocking the inner channel andthe outer channel.

In accordance with another embodiment of the present disclosure, aplurality of adjacent windings of the outer channel each capture thefirst arm and the second arm of adjacent windings of the inner channelwithin the triangular shape, thereby interlocking the inner channel andthe outer channel.

In accordance with another embodiment of the present disclosure, theinner channel has a groove structure formed from a compound fold in thecentral web, the groove structure being disposed intermediate the firstarm and the second arm, the groove structure of the inner channeldefining an outwardly facing groove into which at least one of the firstarm and the second arm of the outer channel is receivable.

In accordance with another embodiment of the present disclosure, theouter channel has a groove structure formed from a compound fold in thecentral web, the groove structure being disposed intermediate the firstarm and the second arm, the groove structure of the outer channeldefining an inwardly facing groove into which at least one of the firstarm and the second arm of the inner channel is receivable.

In accordance with another embodiment of the present disclosure, theinner channel has a groove structure formed from a compound fold in thecentral web, the groove structure being disposed intermediate the firstarm and the second arm. The groove structure of the inner channeldefining an outwardly facing groove into which at least one of the firstarm and the second arm of the outer channel is receivable. The outerchannel having a groove structure formed from a compound fold in thecentral web, the groove structure being disposed intermediate the firstarm and the second arm, the groove structure of the outer channeldefining an inwardly facing groove into which at least one of the firstarm and the second arm of the inner channel is receivable.

In accordance with another embodiment of the present disclosure, theoutwardly facing groove is dimensioned to receive the first arm and thesecond arm of adjacent windings of the outer channel and the inwardlyfacing groove is dimensioned to receive the first arm and the second armof adjacent windings of the inner channel.

In accordance with another embodiment of the present disclosure, atleast one of the first arm and the second arm has a plurality ofopenings formed therein and from which a tab depends at an anglerelative thereto proximate at least one of the openings, at least one ofthe plurality of openings aligning with the tab of an adjacent windingof the channel, the tab inserting into the aligned opening and aiding insecuring adjacent windings of the channel in relative juxtaposition.

In accordance with another embodiment of the present disclosure, a spoolhas an axis, an axial length, an inner surface and a curved outersurface about which material may be wound.

A spirally wound, elongated inner channel has a first central web and afirst pair of arms spaced a first distance from one another, the innerchannel being oriented with the first central web parallel to the axiallength of the spool and with the first pair of arms extending therefromat least partially in a radial direction away from the axis of thespool. The inner channel has a plurality of adjacent windings, the firstcentral web of adjacent windings of spirally wound inner channelcumulatively forming the inner surface. A spirally wound, elongatedouter channel has a second central web and a second pair of arms spaceda second distance from one another, The outer channel is oriented withthe second central web parallel to the axial length of the spool andwith the second pair of arms extending therefrom at least partially in aradial direction towards the axis of the spool. The outer channel has aplurality of adjacent windings, the second central web of adjacentwindings of spirally wound outer channel cumulatively forming the outersurface. At least one of the first arm and the second arm of at leastone of the inner channel and the outer channel being scrolled inwardlytoward the central web.

In accordance with another embodiment of the present disclosure, boththe first arm and the second arm of at least one of the inner channeland the outer channel are scrolled inwardly toward the central webimparting a B-shaped cross-sectional shape.

In accordance with another embodiment of the present disclosure, boththe first arm and the second arm of both the inner channel and the outerchannel are scrolled inwardly toward the central web imparting aB-shaped cross-sectional shape, at least one of the inner channel andthe outer channel having a spacing between the first arm and the secondarm to accommodate at least one of the first arm and the second arm ofthe other of the inner channel and the outer channel therebetween.

In accordance with another embodiment of the present disclosure, boththe inner channel and the outer channel have a spacing between the firstarm and the second arm to accommodate at least one of the first arm andthe second arm of the other of the inner channel and the outer channeltherebetween. The outer channel is wound over the inner channel with oneof the first pair of arms positioned between the second pair of arms,such that adjacent windings of spirally wound outer channel bridgeadjacent windings of spirally wound inner channel limiting axial motionof the outer channel relative to the inner channel and limiting spacingbetween adjacent windings of the inner channel and spacing betweenadjacent windings of the outer channel.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present invention, reference ismade to the following detailed description of exemplary embodimentsconsidered in conjunction with the accompanying drawings.

FIG. 1 is a diagrammatic sequence showing the transition of a flat stripinto a modified C-shaped channel through a sequence of bending steps inaccordance with an embodiment of the present disclosure.

FIG. 2 is a perspective, partially diagrammatic view of the fabricationof a spirally wound core in accordance with an embodiment of the presentdisclosure.

FIG. 3 is a cross-sectional view of the spirally wound core of FIG. 2taken along section lines III-III and looking in the direction of thearrows.

FIG. 4 is a cross-sectional view of a spirally wound core like that ofFIG. 3, but utilizing a channel shape in accordance with anotherembodiment of the present disclosure.

FIG. 5 is a cross-sectional view of a spirally wound core like that ofFIGS. 2 and 3, but utilizing a channel shape in accordance with anotherembodiment of the present disclosure.

FIG. 6 is a diagrammatic sequence showing the transition of a flat stripinto a modified C-shaped channel through a sequence of bending steps andthe winding of the resultant C-channel on a mandrel, in accordance withanother embodiment of the present disclosure.

FIG. 7 is partially diagrammatic view of two steps in the sequence ofthe fabrication of a spirally wound core using the modified C-channel ofFIG. 6 in accordance with an embodiment of the present disclosure.

FIG. 8 is a diagrammatic sequence showing the transition of a flat stripinto a modified C-shaped channel through a sequence of bending steps inaccordance with an embodiment of the present disclosure.

FIG. 9 is a perspective view of a modified C-channel in accordance withan embodiment of the present disclosure.

FIG. 10 is a cross-sectional view of a spirally wound core like that ofFIGS. 2 and 3, but utilizing a channel shape as shown in FIG. 9.

FIG. 11 is a diagrammatic view of an apparatus for forming a spirallywound core from channel in accordance with an embodiment of the presentdisclosure.

FIG. 12 is a cross-sectional view of internal windings of a spirallywound composite core in accordance with another exemplary embodiment ofthe present disclosure.

FIG. 13 is a cross-sectional view of a spirally wound composite core ofFIG. 12, but including exterior windings.

FIG. 14 is a cross-sectional view of a spirally wound composite core inaccordance with another exemplary embodiment of the present disclosureand positioned on a mandrel.

FIG. 15 is a cross-sectional view of a spirally wound composite coreshowing interior and exterior windings in accordance with anotherexemplary embodiment of the present disclosure.

FIG. 16 is a cross-sectional view of a spirally wound composite coreshowing interior and exterior windings in accordance with anotherexemplary embodiment of the present disclosure.

FIG. 17 is a cross-sectional view of a spirally wound core made frommodified channel in accordance with another exemplary embodiment of thepresent disclosure.

FIG. 18 is a cross-sectional view of a spirally wound core made frommodified channel in accordance with another exemplary embodiment of thepresent disclosure.

FIG. 19 is a diagrammatic view of a structure for securing adjacentchannels of a spirally wound core.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

FIG. 1 shows an end-on view of a strip 10, e.g., made from a metal likealuminum, brass, copper or a polymer. In the case of a metal strip 10,the strip 10 is bent continuously or in a sequence of steps into amodified strip or pre-form 12, which, in cross-section (or as seen froman end-on view), has a recessed central web 14 from which extends a pairof straight extensions 16, 18.

The pre-form 12 is then bent (as shown by arrows A, B, C, D) into amodified C-shaped channel 20, which in cross-section, has two arms 22,24 co-extensively extending away from the central web 14 in the samedirection, approximately perpendicular thereto. Opposing end portions 22a, 24 a of the web 14 of the pre-form 12, when bent, form portions ofthe arms proximate the central web 14, which have a spacing S1 betweenthe outer surfaces of end portions 22 a, 24 a, approximating theinterior spacing S2 between the arms 22, 24 proximate the opening of theC-shape. This bending to transition between the strip 10, to thepre-form 12, to the C-channel 20, can be accomplished by passing thestrip 10 through roller dies (not shown) or a pulling it through alubricated stationary die (not shown) or by or other conventional metalforming methods.

In the case of plastic, the C-channel 20 can be formed as a continuousextrusion from a melt or formed from a strip 10 that is deformable andsettable, e.g., a thermoplastic via the application of bending andheating.

FIG. 2 shows the formation of a spirally wound core 26. Moreparticularly, the C-shaped channel 20 is oriented with the arms 22, 24approximately parallel to the outer cylindrical surface 28 s of amandrel 28 and is wound about the mandrel 28 or otherwise urged (e.g.,by a set of roller dies configuring a virtual mandrel) into a spiralshape. As successive turns/windings 20 a, 20 b, . . . 20 x of thespirally wound C-shaped channel 20 are wrapped about the mandrel 28, theopen end of the C-shape defined by the spaced arms 22, 24 (with spacing52) is pushed over the central web 14 and the portions 22 a, 24 a of thearms 22, 24 (with a spacing S1 separating the outer surfaces thereof) ofthe C-channel 20 already wound on the mandrel 28, such that succeedingwindings, e.g., 20 b of the C-channel 20 overlap and grip previouswindings, e.g., 20 a, at the overlap, via friction, surface features oradhesive.

A guide roller 30 urged by force E, e.g., exerted via a resilient memberor hydraulic actuation, may optionally assist in pressing the succeedingwindings 20 a, 20 b . . . 20 x of the C-channel 20 into an overlappingrelationship to form the core 26. Alternatively, a guide surfacetapering toward the core 26 and urging the C-channel 20 in the directionindicated by force E, may be used. A counteracting force F may beapplied by a spring-loaded, rotatable, axially displaceable plate 311(See FIG. 11) to oppose the force E, to compress the adjacent turns 20a, 20 b . . . 20 x into overlapping engagement. Alternatively, the core26 may be compressed by an assembly of rolls. As a further alternative,the C-channel 20 may be partially or completely pre-bent into an arc (toform the spirally wound cylindrically-shaped core 26) by bendingrollers, such as 32 a, 32 b, 32 c. After a given length of core 26 hasbeen built up from the winding of C-channel 20 a, 20 b . . . 20 x, a saw34, a cutting torch (not shown) or other cutting apparatus, is used toseparate a portion of core 26 from the remainder present on the mandrel28 allowing continuous winding of C-channel 20 and the cutting ofsuccessive segments of core 26 for a given application, e.g., for use asspools to wind sheet aluminum.

FIG. 3 shows a portion of a wall 36 of the core 26 in cross-section,showing a plurality of side-by-side, overlapping C-channel windings 20a, 20 b . . . 20 x with the outer arms 24 a . . . 24 x forming an outersurface 38 of the wall 36 of the core 26 (See FIG. 2) and the inner arms22 a . . . 22 x forming an inner surface 40 of the wall 36 of the core26. Each of the C-channel windings 20 a . . . 20 x either overlap, areoverlapped, or both, by an adjacent channel winding(s) 20 b . . . 20x−1. The extent of one overlap 42 x (of channel winding 20 x and 20 x−1)is depicted in dotted lines. The webs 14 a . . . 14 x provide a radiallyextending support, which resists radial forces exerted on the core 26.FIG. 3 illustrates that the outer surface 38 and the inner surface 40are substantially continuous and flat, interrupted only by the jointsbetween adjacent C-channel turns 20 a . . . 20 x. The joints may beminimized by the geometry of the C-channel 20 (to provide a mating fitat the overlap 42) and by the degree that the overlapping C-channelwindings 20 a . . . 20 x are pushed (compressed) into proximity.

FIGS. 4 and 5 illustrate that the dimensions of the C-channel 20 may bevaried to adjust the attributes of the resultant core 26. Morespecifically, FIG. 4 shows that the length of arms 22′ and 24′ may bereduced relative to arm portions 22 a′ and 24 a′ (e.g., in comparison tothe relative sizing shown in FIGS. 1 and 3), such that a given length ofwall 36′ has more C-channel windings 20 a′ . . . 20 x′ and a greaternumber of webs 14′ providing support in a radial direction, given asimilar overlap 42′.

FIG. 5 shows that the overlap 42″ may be increased by enlarging thelength of the arm portions 22 a″ and 24 a″ relative to the length of thearms 22″ and 24″, the overlap 42″representing a double thickness ofC-channel 20″ in the area of the wall 36″ defined by the overlap 42″.

FIG. 6 shows an end-on view of a strip 110, e.g., made from materialsand by methods similar to those described above with respect to theembodiment shown in FIG. 1. The strip 110 may be bent continuously, orin a sequence of steps, into a modified strip or pre-form 112, which, incross-section (or as seen from an end-on view), has a recessed centralweb 114 from which extends a pair of faceted extensions 116, 118. Thepre-form 112 is then bent into a modified C-shaped channel 120, which,in cross-section, has two undulating arms 122, 124 co-extensivelyextending away from the central web 114 in the same general direction,approximately perpendicular thereto. The undulating arms 122, 124 of theC-channel 120 each have a pair of outwardly directed bulges 122 a, 122 band 124 a, 124 b, respectively. A first bulge 122 a, 124 a,respectively, is near the central web 114 and a second bulge 122 b, 124b, respectively, is near the open end of the C-shape and separated fromfirst bulge 112 a, 124 a by an inwardly directed bulge 122 c, 124 c,respectively.

The C-channel 120 is oriented with the arms 122, 124 generally parallelto the outer cylindrical surface of a mandrel 128 and is wound about themandrel 128 or otherwise urged (e.g., by a set of roller diesconfiguring a virtual mandrel) into a spiral shape. As shown in FIG. 7,as successive turns of the spirally wound C-shaped channel 120 arewrapped about the mandrel 128, the open end of the C-shape (defined bythe spaced, undulating arms 122, 124) is pushed over the central web 114of a portion of the C-channel 120 already on the mandrel 128, in amanner similar to that described above relative to FIG. 2, such thatsucceeding windings of the C-channel 120 overlap. FIG. 7 shows theoverlapping of C-channel windings 120 a and 120 b to form a portion of awall 136 of a core like wall 36 of core 26 of FIG. 2, but utilizing theC-channels 120 of FIG. 6.

As shown in FIG. 7, the second bulges e.g., 122 b, 124 b of eachC-channel winding 120 a, 120 b . . . 120 x has a shape similar to thefirst bulges e.g., 122 a, 124 a, but is dimensioned such that the openend of the C-shape of the C-channel windings 120 a, 120 b allows easyinsertion of the central web 114 of an adjacent turn of the C-channel,e.g., 120 a therein, to build-up a spirally wound core, i.e., dimensionS1 is less than S2.

As shown in FIG. 7, subsequent to the insertion/overlapping of adjacentturns of the C-channel 120 a, 120 b . . . 120 x, the second bulges 122b, 124 b of each of the arms 122, 124, respectively, of the C-channels120 a . . . 120 x are urged towards each other by a set of roller dies144, 146 or equivalent means to clamp the over-lapping second bulges 122b, 124 b of a given C-channel, e.g., 120 b, over the first bulges 122 a,124 a of the adjacent C-channel turn, e.g., 120 a, locking the adjacentturns 120 a, 120 b together to resist disassociation by forces exertedon the resultant winding core (like 26 of FIG. 1) in a directionparallel to the axis of the core 26. The over-lapping second bulges 122b, 124 b are dimensioned and shaped such that when they are clamped overthe first bulges 122 a, 124 a, the mating surfaces thereof arecomplementarily shaped and substantially parallel.

FIG. 8 shows an end-on view of a strip 210, e.g., made from materialsand by methods similar to those described above with respect to theembodiment shown in FIGS. 1-7. The strip 210 may be bent continuously orin a sequence of steps into a series of modified strips or pre-forms 212a-212 e and finally, into a modified C-shaped channel 220. The C-channel220 has a central web 214 bounded by two angled slots 215, 217, formedby walls 215 a, 215 b, 215 c and 217 a, 217 b and 217 c, respectively.Two arms 222, 224 extend away from the slot walls 215 c and 217 c,respectively, generally co-extensively and perpendicular to the web 214and in the same general direction. The arms 222, 224 each have aninwardly directed lip 223 and 225, respectively, at the open end of theC-shape, having an angle relative to a corresponding arm 222, 224approximating that of the slots 215, 217.

FIG. 9 shows the C-channel 220 prior to bending. As in theabove-described embodiments, the C-channel is oriented with the arms222, 224 generally parallel to the outer cylindrical surface of amandrel 28 and is wound about the mandrel 28 or otherwise urged (e.g.,by a set of roller dies 32 a-32 c configuring a virtual mandrel) into aspiral shape.

FIG. 10 shows that as successive turns of the spirally wound C-channel220 a, 220 b . . . 220 x are wrapped about the mandrel 228, the inwardlydirected lips, e.g., 223 b, 225 b proximate the open end of theC-channel 220 b are urged/guided into the angled slots 215 a, 217 a inthe central web 214 a portion of the C-channel 220 a already on themandrel 228 by temporary deformation, followed by relaxation of thedeformation to allow a return to an un-deformed configuration viaelastic memory. As elastic memory exerts itself, the lips, e.g., 223 b,225 b converge towards one another in the respective slots 215 a, 217 aand pull successive windings of the C-channel 220 a . . . 220 x towardone another in a self-induced elastic compression. The temporarydeformation of the lips 223, 225 and arms 222, 224 may be done by rollerguides or stationary tapered dies that guide a C-channel 220 into thedeformed position at the time it encounters the mating slots.

Optionally, the slots 215, 217 may be crimped down onto the inwardlydirected lips 223, 225 by a die acting internally to the C-channel 220 bas it is coupled to the prior winding of C-channel 220 a, i.e., bypressing against central web 214 a. Crimping may also be accomplished bya crimping roller pressing the windings 220 a . . . 220 x against themandrel 228 to diminish the distance between walls 222, 224, eitherindependently, or in combination with crimping by an internal die.

FIG. 11 shows an apparatus 300 for forming cores 326 from C-channel 20,120, 220. More particularly, a mandrel 328 is turned by a motor 301 orother drive means, pulling C-channel strand 320 onto the mandrel 328. Inorder to start the continuous production of cores 326, the strand mustbe clamped to the mandrel 328 until sufficient frictional interactionexists between the strand 320 and the mandrel 328 to draw and bend thestrand over the mandrel 328. As the strand of C-channel 320 is drawnonto the mandrel 328, one or more rollers 330 a, 330 b push successivewindings of C-channel into overlapping condition, as described above.The formative, continuous core 326 f may be supported on the mandrel 328and or rotated with the mandrel by rollers 303, 305 that may be drivenor free turning. Brakes 307, 309 may be utilized to restrain the axialmovement of the formative core 326 f to allow compression of theC-channel windings and/or stop the rotation of the mandrel 328 to allowcutting of a core 326 from the formative core 326 f by cutter 334.Alternatively, a core restraint 311, which is selectively rotatable andprojectable/retractable in an axial direction, may be used to pressagainst the formative core 326 f to promote compression of the C-channelwindings and/or to apply a braking force to stop the core 326 f forcutting. As a further alternative, cores 326 may be cut from theformative core 326 f as the formative core 326 f is turned, e.g., by acutting torch that is moved axially to compensate for the axiallyadvancing formative core 326 f, in order to make a straight cut.

FIGS. 12 and 13 show an alternative embodiment of the present disclosurehaving a core 426 with a wall 436 formed from interior windings 420 a .. . 420 x and exterior windings 431 a . . . 431 x−1 of C-channel (420and 431 generally, respectively) shown in cross-section and wound on amandrel 428, an outer surface 428S of which is depicted by a dottedline. The C-channel 420 and 431 may optionally be identical, butoriented in opposite orientations when wound. The C-channel 420 is woundwith the central web 414 thereof oriented generally parallel to theouter surface 428S of the mandrel 428. The arms 422, 424 of theC-channel 420 extend away from the mandrel 428 and are bent toward oneanother (as shown by the arrows on arms 422 x and 424 x of winding 420 xin FIG. 12) either before being wound on the mandrel or afterward, toform an open triangular shape in cross-section (see 420 a . . . 420 x−1in FIG. 12). As shown in FIG. 13, outer windings 431 a . . . 431 x−1 ofC-channel 431 are wound about the interior windings 420 a . . . 420 xwith the arms 433, 435 (See e.g., 431 x−1) pointed toward the mandrel428 and positioned between the open triangular shape of two adjacentinterior windings 420. Subsequent to the winding of the outer C-channel431 onto the interior C-channel 420, in the bridging configurationshown, the arms 433, 435 of the outer C-channel 431 and the arms 422,424 of the inner C-channel 420 are bent to approximate a triangularshape (relative to respective webs 437, 414), interlocking the spirallywound C-channels 420, 431. The webs 437 a . . . 437 x−1 form theexterior wall surface 439 and the webs 414 a . . . 414 x form theinterior wall surface 441 of the core 426. The bending of the respectiveC-channels 420, 431 into a triangular cross-sectional shape may befacilitated by compressing the outer surface 439 toward the innersurface 441. Displacements of the C-channels 420, 431 in a compressivedirection are limited by the arms 422, 424, 433, 435 of the respectivechannels 420, 431 reaching a limit of travel at respective interioracute angles of the triangularly-shaped, mating C-channel.

FIG. 14 shows an alternative embodiment of the present disclosure formaking a core 526 on mandrel 528 with a wall 536 formed from interiorwindings 550 a . . . 550 x−1 and exterior windings 550 a′ . . . 550 x−1′of E-channel (550 and 550′ generally, respectively, with exteriorwindings 550 a′ . . . 550 x−1′ shown in phantom) wound on a mandrel 528,having an outer surface 528S. The E-channel 550 has a pair of arms 553,555 extending from corresponding web portions 557, 559. A centralU-portion 561 defines a central cavity 563. A pair of return U-portions565, 567 connect the central U-portion 561 to the web portions 557, 559,respectively. The E-channel 550 and 550′ may optionally be identical andhave the same type of arms, 553, 555, web portions 557, 559, U-portion561 and return U-portions 565, 567, but oriented oppositely when woundto form the core 526. While the E-channel 550, 550′ depicted in FIG. 14is symmetrical about the U-portion 561, which is denominated a “centralU-portion,” optionally, the U-portion 561 could be shifted off-center,such that web portions 557 and 559 would be of unequal length.

The E-channel 550 is wound with the web portions 557, 559 thereoforiented generally parallel to the outer surface 5285 of the mandrel 528a and with the arms 553, 555 extending away from the mandrel 528.Successive windings 550 a, 550 b, 550 x−1, etc. are wound in closeproximity, one to another, such that the arms, e.g., 553 b, 555 a ofadjacent E channel windings 550 a and 550 b touch, or are closelyspaced. Since the core 526 shown in FIG. 14 is a spirally woundstructure, the lower portion of the core 526 on the mandrel 528 has thesame structures that are present on the opposite side of the core 526,displaced axially. Once the inner windings 550 a . . . 550 x−1 are woundonto the mandrel 528, outer windings 550 a′ . . . 550 x−1′ of E-channel550′ are wound about the interior windings 550 a . . . 550 x with thearms 553′, 555′ pointed toward the mandrel 528 and positioned to bereceived in the central cavity 563 of central U-portions 561 of theinner windings of E-channel 550 already on the mandrel 528. For example,arm 555 a′ of winding 550 a′ is received in central cavity 563 a ofE-channel 550 a. Simultaneously, arm 555 a of winding 550 a and arm 553b of winding 550 b are received in central cavity 563 a′ of outerwinding 550 a′. Central cavity 563 a′ may optionally be dimensioned tosqueeze arms 553 b and 555 a together and the U-portions 563 a′, 565 a′and 567 a′ may exhibit elasticity to enable deformation of U-portion 563a′ to accommodate arms 553 b and 555 a, which are then urged togetherunder the influence of elastic memory. This relationship between arms553, 555 and U-portion 561 is exhibited along the width of the core 526,alternatively, by the inner and outer windings of E-channel 550, 550 a,drawing the core 526 into axial compression. The webs 557′ and 559′ formthe majority of the exterior wall surface 539 and the webs 557 and 559form the interior wall surface 541 of the core 526. In the case of boththe outer wall surface 539 and the inner wall surface 541, the centralU-portions 561 and central U-portions 561′ form a minor portion of therespective surfaces. The overlaying/meshing of the respective E-channels550, 550′ may be facilitated by compressing the outer surface 539 towardthe inner surface 541, e.g., with a press roller or tapered guidesurface (not shown) or by exerting a tension on the E-channel 550′ as itis wound to make the core 526. The length of the arms 553, 555 and webportions 557, 559 can be varied to provide a selected number of radialsupports for a given length of core 526 and for controlling the wall 536thickness, each mating junction of arms, e.g., 553, 555 with centralU-portions 561′ and return U-portions 565′, 567′ providing six radialsupport members.

FIG. 15 shows an alternative embodiment of the present disclosurewherein a core 626 has a wall 636 formed from inner and outer windings,e.g., 670 a, 670 a′ of B-channel 670. The B-channel 670 has a centralweb 672 bounded by end scrolls 674, 676. The interior windings 670 a . .. 670 d of B-channel 670 are spirally wound on a mandrel 628—likemandrel 528 of FIG. 14, with the web, e.g., 672 a facing the mandrel andthe scrolls, e.g., 674 a, 676 a pointing away from the mandrel 628. Oneor more exterior windings 670 a′ . . . 670 c′ of exterior B channel 670are wound over the interior B-channel 670 with the webs 672 a′ . . . 672c′ thereof pointed away from the mandrel 628 and the scrolls, e.g., 674a′ and 676 a′ pointed toward the mandrel 628. As shown, the scrolls 674a′ . . . 674 c′ and 676 a′ . . . 676 e of the outer windings 670 a′ . .. 670 c′ insert between the scrolls 674 a . . . 674 d and 676 a . . .676 d of the inner windings 670 a . . . 670 d, each bridging theadjacent windings of the other and with the scrolls interleaved. Forexample, outer winding 670 a′ bridges adjacent inner windings 670 a and670 b, with scroll 676 a′ inserted between scrolls 674 a and 676 ainterleaved with scroll 674 a. Scroll 674 a′ is interleaved with scroll676 b of inner winding 670 b. The composite core 626 has an inner wallsurface 641 formed by the webs 672 a . . . 672 d of the interiorB-channel windings 670 a . . . 670 d and an exterior surface 639 formedby the webs 672 a′ . . . 672 e of the exterior windings 670 a′ . . . 670e of the B-channel 670. In this embodiment, as in other embodiments ofthe present disclosure, the exterior windings 670 a′ . . . 670 c′ of theB-channel 670 and/or the interior windings 670 a . . . 670 d of theB-channel 670 may be secured to one another by welding, riveting,adhesives or fasteners at one or more locations, e.g., at the ends, toprevent unwinding.

FIG. 16 shows an alternative embodiment of the present disclosuresimilar in some ways to that of FIG. 15, in that the inner B-channels770 a . . . 770 c are similarly dimensioned as the exterior B-channels774 a . . . 774 c, e.g., identical, but reversed in orientation duringwinding. The distance W3 between the scrolls 777, 779 may optionally beapproximately twice that of the width W4 of the scrolls 777, 779, suchthat the scrolls 777, 779 of adjacent interior B-channels 770 may beaccommodated between the spacing of width W3 between scrolls of anexterior B-channel and vice versa, without interleaving. The scrolls,e.g., 777, 779 of the B-channel 774, provide radial reinforcement of thecore 726 when wound to form composite wall 736, but also retainelasticity since the scrolls 777, 779 are not attached to web 775,lending resistance to radial deformation of the core 726, as well as adegree of elasticity permitting deformation and recovery after deformingforces are removed.

FIG. 17 shows an alternative embodiment of the present disclosure havinga core 826 with a wall 836 formed from a spirally wound, modifiedS-channel 827. The core 826 is wound around a mandrel 828, as inpreviously described embodiments. The S-channel, in cross-section,features a central web 814 from which extends top arm 822 and bottom arm824, the bottom arm 824 extending away from the central web 814 in asubstantially opposite direction compared to the top arm 822. Anabutment arm 829 extends from an end of the top arm 822 distal to thecentral web 814. A diagonal arm 833 extends at an acute angle from theend of the bottom arm 824 and directed back toward the central web 814.A pushing arm 835 extends from the end of the diagonal arm 833 distal tothe bottom arm 824. The modified S-channel 827 is wound on the mandrel828 with the top and bottom arms 822, 824 thereof oriented generallyparallel to the outer surface 8285. Subsequent windings, e.g., 827 boverlap prior windings, e.g., 827 a with the abutment arm 829 binserting between the junction of the diagonal arm 833 a and pushing arm835 a and the web 814 a of the previous winding 827 a of modifiedS-channel. As the subsequent winding, e.g., 827 b is drawn down tightlyonto the mandrel 828, the pushing arm, e.g., 835 a of the prior windingof modified S-channel, e.g., 827 a is trapped in the corner formedbetween abutment arm 829 b and top arm 822 b, such that the diagonal arm833 a pushes the winding 827 b in an axial direction toward the priorwinding 827 a. The top arms 822 a . . . 822 c and the bottom arms 824 a. . . 824 c, respectively, form the exterior wall surface 839 and theinterior wall surface 841 of the core 826. Displacements of the core 826in a radially compressive direction are limited by the central webs 814a . . . 814 c, as well as by the diagonal arms 833 a . . . 833 c and thepushing arms 835 a . . . 835 c, the latter two elements having a degreeof elasticity and elastic memory that may absorb energy and restore inresponse to compressive forces.

FIG. 18 shows an alternative embodiment of the present disclosurewherein a wall 936 of the core 926 in cross-section, has a plurality ofside-by-side, overlapping modified C-channel windings 920 a, 920 b . . .920 x. The outer arms 924 a . . . 924 x form an outer surface 938 of thewall 936 of the core 926 and the inner arms 922 a . . . 922 x form aninner surface 940 of the wall 936 of the core 926. Each of the C-channelwindings 920 a . . . 920 x either overlap, are overlapped, or both, byan adjacent channel winding(s) 920 b . . . 920 x similar to theembodiment shown and described above in FIGS. 1 and 3. The outer arms924 a . . . 924 x have an inwardly directed grip arm 925 a . . . 925 xthat is received in a groove 927 a . . . 927 x on the adjacent winding,e.g., grip arm 925 b is received in groove 927 a. The angle of the griparm 925 x relative to the outer arm 924 x may be varied. As shown bywinding 920 x, the C-channel may be wound onto the mandrel 928 andpositioned against an adjacent winding 920 x−1 with the outer arm 924 xdisplaced upwardly, out of parallel with the inner arm 922 x tofacilitate adjacent positioning. The outer arm 924 x is then bent down,e.g., by a pressure roller or guide surface, such that the grip arm 925x enters the groove 927 x−1. Alternatively, rollers and guide surfacescan be omitted if the C-channel 920 is fed onto the mandrel 828 with thearms 922 a . . . 922 x distal to the mandrel and the arms 924 a . . .924 x proximate the mandrel, such that the arms 924 a . . . 924 x areflattened down as winding takes place. As shown in FIG. 18, the spirallywound C-channel 920 defines a continuous spiral hollow 950 which extendsthrough the core 926. This type of hollow may be also be observed in theembodiments described above relative to FIGS. 1-17.

FIG. 19 shows a channel 1020 in accordance with an alternativeembodiment of the present disclosure and having at least one opening1081 punched therein leaving a hanging tab 1083 attached at one edge1082. The tab 1083 may be formed in a portion 1024 of the channel 1020that, when wound to form a spiral core, overlaps another portion 1024 aof the adjacent channel 1020 winding. As shown in FIG. 19 the otherportion 1024 a which is overlapped may also have an opening 1087 oropenings formed therein, such that the tab 1083 of the overlappingportion 1024 extends into the opening 1087 made in the overlappedportion 1024 a, stabilizing relative motion in the direction S betweenthe overlapping portion 1024 and the overlapped portion 1024 a. Moreparticularly, the periphery of the opening 1087 in the overlappedportion 1024 a will encounter the tab 1083 of the overlapping portion1024 to limit the relative motion. This feature can be utilized in areasof overlap such as the overlap 42 shown in FIG. 5, where the upper arm24″ and the reduced spacing portion 24 a″ can be punched to create oneor more tabs 1083, 1085 and openings 1081, 1087, respectively, which canbe aligned, such that the tab 1083 of the overlapping portion 24″extends into the opening 1087 formed in the overlapped portion 24 a″. Inthis application, the tab 1083 will aid in preventing adjacent windingsof C-channel from disassociating. The openings 1081, 1087/tabs 1083,1085 may be formed prior to bending or winding the C-channel, duringwinding, or after winding. The aligned tabs 1083 and openings 1087 mayalso be utilized with other of the embodiments depicted and describedherein.

As described above and shown in the Figures, the term “C-channel” hasbeen used and is intended to describe a variety of channels having a Cor modified C shape. The C-shape of the above-described C-channels has apair of arms extending from a web, with each arm having a direction ofextension with a component of direction parallel to the other arm of thepair. The arms are, in this sense, “parallel.” One or both of the armsmay have one or more facets or curves, such that they are not completelystraight, but nevertheless can be observed to have an average or generaldirection. Alternatively, the arms may be straight. An aspect of thecores described above which are formed from a spirally wound C-channelwith the arms extending in a direction having a component of extensionin parallel with the axis of the resultant core is that the webs thereofextend outwardly from the axis of the resultant spool/core with acomponent of extension perpendicular to the axis. The term “radial” istherefore intended to encompass extension perpendicular to the axis orextension which has at least a component of direction perpendicular tothe axis of the spool/core. Cores made from the disclosed C-channele.g., 20, 120, 220, 320, 420, 550, 671, 770, 827, 927 provide advantagesin that the outer surface of the core (that which is in contact with thewound sheet or foil product) can be manufactured with a smooth face.This smoothness prevents the loss of inner windings of product that iswrapped on the core, e.g., 26, 827, 326. The webs, e.g., 14, 114, 214provide an “I-beam” structure, a radially oriented spiral web, makingthe core stronger and more rigid for a given weight. The interlockingC-channels, e.g., 20, 120, 220, 320, 927 can be wound onto the mandrel28 with a specified axial overlapping, such that the spacing of theradial webs 14, 114, 214 and the wall 36, 136, 236 bending stiffness areeasily adjusted/set for a given application. Optionally, the axialoverlap of C-channels, e.g., 20, 120 could vary across the axial lengthof the core. This provides the option of making a portion of the core,e.g., the ends, stronger relative to the remainder, attributable togreater overlap. The cores, e.g., 26, 326, 926 have a smooth insidediameter (ID), reducing the chance that the ID of the core will bedamaged by handling equipment and facilitating interaction between thecore 26, 326 and handling.

Cores 26, 326 made from the disclosed C-channel 20, 120 provide a doublewalled thickness to the desired degree via a selective degree ofoverlap. Double wrapped or composite cores 426, 526, 626 and 726 providea double thickness wall 436, 536, 636, 736 with a variety ofintermediate structural features to enhance strength and rigidity. Thecores 626, 726 and 826 have resilient members that impart a degree ofresilience to deformation forces. The core, e.g., 26, 326, 826 may bemade from recyclable material and may be formed from the samecomposition as the sheet product being shipped. For example, an aluminumcore 26, 326, 736 may be used to hold aluminum sheet. It is possible toconstruct cores 26, 326, 736 using sheet metal, which for variousreasons, such as width, gauge, crystallographic texture, or staining,does not meet customer specifications and which would be scrapped. Useof scrap coils provides inexpensive and readily available feedstockmaterial for the manufacture of the winding cores 26, 326. An all-metalcore 26, 326, 626, 826 e.g., an all-aluminum core, can be convenientlyrecycled if it is constructed of the same or similar alloy from whichthe sheet product is produced, e.g., unused portions of the coils ofsheet product on the core 26, 326 can be recycled together with the core26, 326.

It is understood that the embodiments described herein are merelyexemplary and that a person skilled in the art may make many variationsand modifications without departing from the spirit and scope of theclaimed subject matter. All such variations and modifications areintended to be included within the scope of the appended claims.

1. A spool having an axis, an axial length, an inner surface and acurved outer surface about which material may be wound, comprising: aspirally wound, elongated channel having a C-shaped cross-section with apair of arms extending from a central web, the channel being orientedwith the pair of arms having a component of extension parallel to theaxial length of the spool and with the central web extending radiallyrelative to the axis of the spool, the channel having a plurality ofadjacent windings, a first of the arms of spirally wound channelcumulatively forming the outer surface and a second of the arms ofspirally wound channel cumulatively forming the inner surface, the firstarm and the second arm spaced apart a distance approximating the widthof the central web, such that the central web of the windings of thechannel is receivable between the arms of adjacent windings and isretainable therein to establish an overlap of windings of the channel inthe axial direction.
 2. The spool of claim 1, wherein each of the firstarm and the second arm has a first portion extending from the centralweb and a second portion extending from a free end of the arm to atransition portion extending between the first portion and the secondportion, the second portion of the first arm and the second portion ofthe second arm having a first spacing there between approximating asecond spacing between an exterior surface of the first portion of thefirst arm and an exterior surface of the first portion of the secondarm.
 3. The spool of claim 2, wherein the channel exhibits a thirdspacing between an exterior surface of the second portion of the firstarm and an exterior surface of the second portion of the second arm andthe difference between the second spacing and the third spacingapproximates a radial thickness of the second portion.
 4. The spool ofclaim 3, wherein the outer surface is cylindrical and smooth.
 5. Thespool of claim 1, wherein at least one of the first arm and the secondarm has an undulating form in cross-section, an interior surface of theundulating form engaging and mating with an exterior surface of anundulating form of an adjacent winding of the channel of the spool. 6.The spool of claim 5, wherein both of the first arm and the second armhave an undulating form in cross-section.
 7. The spool of claim 6,wherein the undulating form has first and second bulges separated by avalley, the first bulge extending from the central web.
 8. The spool ofclaim 1, wherein the channel has at least one slot extending into thecentral web, the slot capable of receiving an end of at least one of thefirst arm and the second arm of an adjacent winding of the channel. 9.The spool of claim 8, wherein the slot is blind and is angled at anacute interior angle relative to the central web.
 10. The spool of claim9, wherein the channel has a pair of slots, a first slot disposedproximate a junction of the first arm with the central web and a secondslot disposed proximate a junction of the second arm with the centralweb.
 11. The spool of claim 10, wherein the first arm and the second armeach have an angled portion proximate a free end thereof which insertsinto a corresponding one of the first slot and the second slot of anadjacent winding of the channel.
 12. The spool of claim 1, wherein thechannel has at least one groove in at least one of the first arm and thesecond arm disposed proximate the central web, and wherein at least oneof the first arm and the second arm has an angled portion proximate afree end thereof which inserts into the groove of an adjacent winding ofthe channel.
 13. The spool of claim 12, wherein the at least one grooveis disposed between the central web and the first arm.
 14. The spool ofclaim 13, wherein the at least one groove has a generally V-shapedcross-section.
 15. The spool of claim 1, wherein at least one of thefirst arm and the second arm has a plurality of openings formed thereinand from which a tab depends at an angle relative thereto proximate atleast one of the openings, at least one of the plurality of openingsaligning with the tab of an adjacent winding of the channel, the tabinserting into the aligned opening and aiding in securing adjacentwindings of the channel in relative juxtaposition.
 16. A spool having anaxis, an axial length, an inner surface and a curved outer surface aboutwhich material may be wound, comprising: a spirally wound, elongatedchannel having an S-shaped cross-section with a pair of arms extendingfrom a central web and having a component of extension in oppositedirections, a first arm of the pair of arms having a first extensionextending from an end of the first arm distal to the central web at anangle relative to the first arm and forming a top portion of theS-shape, a second arm of the pair of arms having a second extensionextending from an end of the second arm distal to the central web at anangle relative to the second arm and forming a bottom portion of theS-shape, the second extension pointing towards a portion of the centralweb, a distal end of the second extension being distal to the second armand spaced from the central web by a first spacing, the channel beingoriented with the pair of arms having a component of extension parallelto the axial length of the spool and with the central web extendingradially relative to the axis of the spool, the channel having aplurality of adjacent windings, the first arm of adjacent windings ofspirally wound channel cumulatively forming the outer surface and thesecond arm of adjacent windings of spirally wound channel cumulativelyforming the inner surface, the first extension receivable between thedistal end of the second extension and the central web of an adjacentwinding to interlock therewith and establish an overlap in the axialdirection.
 17. The spool of claim 16, wherein the distal end of thesecond extension pushes the first extension of an adjacent winding ofthe channel toward the central web.
 18. The spool of claim 17, furthercomprising a pushing arm extending from the distal end of the secondextension, the pushing arm being captured in the interior angle formedbetween the first extension and the first arm.
 19. A spool having anaxis, an axial length, an inner surface and a curved outer surface aboutwhich material may be wound, comprising: a spirally wound, elongatedinner channel having a first central web and a first pair of arms spaceda first distance from one another, the inner channel being oriented withthe first central web having a component of extension parallel to theaxial length of the spool and with the first pair of arms extendingtherefrom at least partially in a radial direction away from the axis ofthe spool, the inner channel having a plurality of adjacent windings,the first central web of adjacent windings of spirally wound innerchannel cumulatively forming the inner surface; a spirally wound,elongated outer channel having a second central web and a second pair ofarms spaced a second distance from one another, the outer channel beingoriented with the second central web generally parallel to the axiallength of the spool and with the second pair of arms extending therefromat least partially in a radial direction towards the axis of the spool,the outer channel having a plurality of adjacent windings, the secondcentral web of adjacent windings of spirally wound outer channelcumulatively forming the outer surface, the outer channel wound over theinner channel with one of the first pair of arms positioned between thesecond pair of arms, such that adjacent windings of spirally wound outerchannel bridge adjacent windings of spirally wound inner channellimiting axial motion of the outer channel relative to the inner channeland limiting spacing between adjacent windings of the inner channel andspacing between adjacent windings of the outer channel.
 20. The spool ofclaim 19, wherein the first pair of arms converge towards one another ata distal end thereof and the second pair of arms converge towards oneanother at a distal end thereof, the first pair of arms with the firstcentral web forming a triangular shape and the second pair of arms withthe second central web forming a triangular shape.
 21. The spool ofclaim 20, wherein a first arm of a first adjacent winding of the outerchannel and a second arm of a second adjacent winding of the outerchannel are disposed within a first triangular shape of a first adjacentwinding of the inner channel.
 22. The spool of claim 20, wherein aplurality of adjacent windings of the inner channel each capture thefirst arm and the second arm of adjacent windings of the outer channelwithin the triangular shape, thereby interlocking the inner channel andthe outer channel.
 23. The spool of claim 22, wherein a plurality ofadjacent windings of the outer channel each capture the first arm andthe second arm of adjacent windings of the inner channel within thetriangular shape, thereby interlocking the inner channel and the outerchannel.
 24. The spool of claim 19, wherein the inner channel has agroove structure formed from a compound fold in the central web, thegroove structure being disposed intermediate the first arm and thesecond arm, the groove structure of the inner channel defining anoutwardly facing groove into which at least one of the first arm and thesecond arm of the outer channel is receivable.
 25. The spool of claim19, wherein the outer channel has a groove structure formed from acompound fold in the central web, the groove structure being disposedintermediate the first arm and the second arm, the groove structure ofthe outer channel defining an inwardly facing groove into which at leastone of the first arm and the second arm of the inner channel isreceivable.
 26. The spool of claim 19, wherein the inner channel has agroove structure formed from a compound fold in the central web, thegroove structure being disposed intermediate the first arm and thesecond arm, the groove structure of the inner channel defining anoutwardly facing groove into which at least one of the first arm and thesecond arm of the outer channel is receivable and wherein the outerchannel has a groove structure formed from a compound fold in thecentral web, the groove structure being disposed intermediate the firstarm and the second arm, the groove structure of the outer channeldefining an inwardly facing groove into which at least one of the firstarm and the second arm of the inner channel is receivable.
 27. The spoolof claim 26, wherein the outwardly facing groove is dimensioned toreceive the first arm and the second arm of adjacent windings of theouter channel and the inwardly facing groove is dimensioned to receivethe first arm and the second arm of adjacent windings of the innerchannel.
 28. The spool of claim 19, wherein at least one of the firstarm and the second arm has a plurality of openings formed therein andfrom which a tab depends at an angle relative thereto proximate at leastone of the openings, at least one of the plurality of openings aligningwith the tab of an adjacent winding of the channel, the tab insertinginto the aligned opening and aiding in securing adjacent windings of thechannel in relative juxtaposition.
 29. A spool having an axis, an axiallength, an inner surface and a curved outer surface about which materialmay be wound, comprising: a spirally wound, elongated inner channelhaving a first central web and a first pair of arms spaced a firstdistance from one another, the inner channel being oriented with thefirst central web parallel to the axial length of the spool and with thefirst pair of arms extending therefrom at least partially in a radialdirection away from the axis of the spool, the inner channel having aplurality of adjacent windings, the first central web of adjacentwindings of spirally wound inner channel cumulatively forming the innersurface; a spirally wound, elongated outer channel having a secondcentral web and a second pair of arms spaced a second distance from oneanother, the outer channel being oriented with the second central webparallel to the axial length of the spool and with the second pair ofarms extending therefrom at least partially in a radial directiontowards the axis of the spool, the outer channel having a plurality ofadjacent windings, the second central web of adjacent windings ofspirally wound outer channel cumulatively forming the outer surface, atleast one of the first arm and the second arm of at least one of theinner channel and the outer channel being scrolled inwardly toward thecentral web.
 30. The spool of claim 29, wherein both the first arm andthe second arm of at least one of the inner channel and the outerchannel are scrolled inwardly toward the central web imparting aB-shaped cross-sectional shape.
 31. The spool of claim 30, wherein boththe first arm and the second arm of both the inner channel and the outerchannel are scrolled inwardly toward the central web imparting aB-shaped cross-sectional shape, at least one of the inner channel andthe outer channel having a spacing between the first arm and the secondarm to accommodate at least one of the first arm and the second arm ofthe other of the inner channel and the outer channel therebetween. 32.The spool of claim 31, wherein both the inner channel and the outerchannel have a spacing between the first arm and the second arm toaccommodate at least one of the first arm and the second arm of theother of the inner channel and the outer channel therebetween, andwherein the outer channel is wound over the inner channel with one ofthe first pair of arms positioned between the second pair of arms, suchthat adjacent windings of spirally wound outer channel bridge adjacentwindings of spirally wound inner channel limiting axial motion of theouter channel relative to the inner channel and limiting spacing betweenadjacent windings of the inner channel and spacing between adjacentwindings of the outer channel.
 33. The spool of claim 1, wherein theoverlapped windings of C-channel define an internal spiral hollowextending through the spool.